DE102019007092A1 - 3D printing process and 3D printing device - Google Patents

Abstract

A 3D printing method for the additive manufacturing of a propellant charge for a solid-state engine comprises layer-by-layer deposition of an extrudable modeling material in material layers, the extrudable modeling material comprising at least two different hardenable fuel mixtures, with a first hardenable fuel mixture in first areas of the material layers and a first hardenable fuel mixture in second areas of the material layers differ from the first areas, a second hardenable fuel mixture is deposited, wherein the first areas and the second areas are arranged in the material layers for setting a predetermined thrust course of the solid-state engine; and curing the extrudable modeling material in the layers of material to form the propellant charge.

Description

The present invention relates to a 3D printing method for the additive manufacturing of a propellant charge for a solid-state engine. The present invention also relates to a 3D printing device for the additive manufacture of a propellant charge for a solid-state engine using such a 3D printing method.

In generative or additive manufacturing processes, also generally referred to as “3D printing processes”, starting from a digitized geometric model of an object, one or more starting materials are sequentially stacked in layers and cured. In fused deposition modeling (FDM), for example, a component is built up in layers from a modeling material, for example a plastic or a metal, in that the modeling material is pressed out of a nozzle in a flowable or more generally in an extrudable form and onto a Underlay is applied, which results in a solid, coherent component after cooling. 3D printing offers exceptional freedom of design and allows, among other things, objects to be produced with manageable effort that could not be produced using conventional methods or only with considerable effort. For this reason, 3D printing processes are currently widespread in industrial design, in the automotive industry, the aerospace industry or in general in industrial product development, in which a resource-efficient process chain is used for the needs-based small and large-scale production of individualized components.

It is sometimes proposed to produce propellant charges for solid-state engines with such or similar extrusion-based 3D printing processes, see for example the publication Chandru et al., "Additive Manufacturing of Solid Rocket Propellant Grains," Journal of Propulsion and Power, Volume 34, No. 4, 2018 . These methods offer advantages over conventional methods, in which targeted thrust courses from solid-state engines are only possible with great effort. Typically, propellant charges for solid-state propulsion systems are shaped in such conventional processes in special, cost-intensive molding tools. Often it is also necessary to first produce partial propellant charges, which then have to be reworked in further work steps and first put together to form final propellant charges. This makes the corresponding conventional methods even more time-consuming and error-prone.

Against this background, the present invention is based on the object of finding more flexible solutions for the production of propellant charges using additive processes.

According to the invention, this object is achieved by a 3D printing method with the features of claim 1 and by a 3D printing device with the features of claim 9.

Accordingly, a 3D printing process for the additive manufacturing of a propellant charge for a solid-state engine is provided. The 3-D printing process comprises laying down an extrudable modeling material in layers in layers of material, the extrudable modeling material comprising at least two different hardenable fuel mixtures, a first hardenable fuel mixture in first areas of the material layers and a first hardenable fuel mixture in second areas of the material layers that differ from the first areas second hardenable fuel mixture is deposited, wherein the first areas and the second areas are arranged in the material layers for setting a predetermined thrust course of the solid-state engine; and curing the extrudable modeling material in the layers of material to form the propellant charge.

Furthermore, a 3D printing device for the additive manufacture of a propellant charge for a solid-state engine using a 3D printing method according to the invention is provided.

Furthermore, a computer-readable medium is provided on which computer-executable instructions are stored which, when executed by means of a data processing device, cause the data processing device to execute a 3D printing method according to the invention.

One idea on which the present invention is based consists in realizing any desired thrust curves for engines without molding tools by deliberately depositing several fuel mixtures with different properties in layers using an additive method and varying them in the process. Different thrust courses can be set by appropriate arrangement or distribution of areas with the respective fuel mixtures. The corresponding distribution of the fuel mixtures in the material layers or material layers can be calculated, for example, with appropriate software for the desired or predetermined thrust course. Both the spatial distribution of the fuel mixtures and their chronological combustion sequence have an influence on the thrust curve. Added to this is the weight loss that occurs during the burn-off. Both aspects can be taken into account by the software in the course of setting up the given thrust curve.

With the method according to the invention and the device according to the invention, the most varied of properties can be generated in a propellant charge in a simple, coherent method. 3D printing processes are particularly advantageous because they enable the production of three-dimensional components in primary molding processes without the need for special production tools that are tailored to the external shape of the components. This enables highly efficient, material-saving and time-saving manufacturing processes for parts and components. Such 3D printing processes are particularly advantageous for the production of propellant charges, since complex geometries, for example with undercut geometries, can also be implemented without great effort. Furthermore, additional materials can easily be introduced into a propellant charge in this way.

3D printing processes in the sense of the present application include all generative or additive manufacturing processes in which, on the basis of geometric models, objects of predefined shape made from shapeless materials such as liquids or shape-neutral semi-finished products such as strip or wire-shaped material by means of chemical and / or physical processes in a special additive manufacturing system. 3D printing processes within the meaning of the present application use additive processes in which the starting material is sequentially built up in layers in predetermined shapes. In particular, such 3D printing processes include extrusion-based additive processes.

Advantageous refinements and developments emerge from the further subclaims and from the description with reference to the figures.

According to a further development, the extrudable modeling material can be deposited in such a way that an inhomogeneous fuel distribution arises in the propellant charge.

According to one development, the different hardenable fuel mixtures can have different thrust powers and / or burn rates.

By appropriate, advantageous selection of both the respective thrust power and / or the respective burn rate, the time course of the thrust and its spatial and temporal power distribution can be adjusted. For example, a first fuel mixture with a first thrust power for a first thrust phase can be positioned in front layers of the propellant charge in relation to an ejection direction. In addition, a second fuel mixture with a second thrust can be provided in the rear layers of the propellant charge in relation to the direction of ejection, wherein the second thrust can be configured to be smaller than the first thrust. In this case, the propellant charge thus delivers a two-stage thrust course with a higher thrust power in a first phase of the temporal burning sequence. Alternatively or additionally, for example, the second fuel mixture can be designed with continuously decreasing thrust power, so that a uniform speed of the missile is achieved (a decrease in weight increases the thrust power).

According to a further development, the extrudable modeling material can furthermore comprise a hardenable inert material. The curable inert material can be deposited in third areas of the material layers that differ from the first areas and the second areas. After curing, the inert material can define inert areas in the propellant charge.

In addition to fuel mixtures with different properties, inert, i.e. non-energetic or reactive materials or substances can also be introduced into the propellant charge in a targeted manner. For example, areas in which fuel mixtures are not required can be left out. In a specific example, the course of thrust can thus be specifically interrupted and / or contained.

According to one development, the 3-D printing method can furthermore include depositing an ignition material in the material layers to form an igniter for igniting the propellant charge of the solid-state engine.

In principle, the ignition material can also be processed in extrudable form as well as stored and cured additively. For example, the 3D printing device can have a dedicated print head for this purpose. Alternatively or additionally, however, the ignition material can also be applied in solid form on, under and / or next to layers of fuel that have already been deposited.

According to a further development, the extrudable modeling material can be deposited directly into an engine casing of the solid-state engine.

In this advantageous development, the propellant charge is thus printed directly into the engine casing and thus the solid-state engine. Alternatively, it can of course also be provided to first print a propellant charge and to introduce this into an engine casing of a solid-state engine at a later point in time of manufacture.

According to a further development, the extrudable modeling material can comprise at least a third hardenable fuel mixture. The third curable propellant mixture can have a higher burn rate than the first curable propellant mixture and the second curable propellant mixture. The third hardenable propellant mixture can be deposited in the material layers in such a way that an ignition channel with the third propellant mixture is formed in the propellant charge.

In this development, channels can thus be introduced into the propellant charge in a targeted manner at a high burning rate. This enables, for example, a more homogeneous ignition that can be initiated by an igniter (for example, the igniter can be positioned adjacent to the ignition channel).

According to a further development, material-free channels can be formed in the propellant charge by material cutouts in the material layers.

Inert areas in the propellant charge can thus be achieved on the one hand by the targeted introduction of inert materials. On the other hand, specific cavities can also be provided, which can also influence the thrust progression and / or the thrust performance.

According to a further development, the 3D printing device can have a print head. The print head can comprise a material mixer for mixing a fuel with a binder, a hardener and / or an additive to form a fuel mixture. The print head can further comprise a print nozzle for depositing the fuel mixture. Alternatively, however, a premixed fuel mixture can also be used directly.

According to a further development, the binder can have a UV-curing binder. This is an advantageous example of a suitable curing mechanism. Alternatively or additionally, depending on the application, the competent person will take into account further hardening processes, such as mechanical, e.g. by means of pressure, chemical, e.g. by means of hardener, physical, e.g. by means of heat, time, chemical, etc.

In this case, the 3D printing device can include UV lighting, with the aid of which the UV-curing binder and thus the corresponding fuel mixture can be cured, for example immediately after exiting a printing nozzle of the 3D printing device.

According to a further development, the 3D printing device can have a separate print head for each fuel mixture and / or for a hardenable inert material. In principle, however, a single print head can also be designed to print different fuel mixtures and possibly also the inert material.

According to a further development, the 3D printing device can furthermore comprise an alignment device. The alignment device can be designed to align an engine casing of the solid-state engine for the direct deposit of the extrudable modeling material in the engine casing. For example, the alignment device can be designed to tilt, rotate and / or align the engine casing along a plurality of spatial axes.

This is particularly advantageous in order to print the propellant charge directly into the engine casing. For example, the 3D printing device can enable storage along at least three axes. In addition, the alignment device can now rotate the engine casing about a further axis in order to facilitate the introduction of the propellant charge into the engine casing. It will be clear to the person skilled in the art that the 3D printing device can also have further degrees of freedom or axes. For example, the print head can be designed to be inclined or tiltable about a fifth axis in order to further facilitate the introduction of the propellant charge.

The above configurations and developments can be combined with one another as desired, provided that it makes sense. Further possible configurations, developments and implementations of the invention also include combinations, not explicitly mentioned, of features of the invention described above or below with regard to the exemplary embodiments. In particular, the person skilled in the art will also add individual aspects as improvements or additions to the respective basic form of the present invention.

• 1 schematische Ansicht einer 3D-Druckvorrichtung zur additiven Fertigung einer Treibladung für ein Festkörpertriebwerk gemäß einer Ausführungsform der Erfindung; und
• 2 schematisches Ablaufdiagramm eines 3D-Druckverfahrens mit der 3D-Druckvorrichtung aus 1.

The present invention is explained in more detail below with reference to the exemplary embodiments specified in the schematic figures. It shows:

• 1 schematic view of a 3D printing device for additive manufacturing of a propellant charge for a solid-state engine according to an embodiment of the invention; and
• 2 schematic flow diagram of a 3D printing process with the 3D printing device 1 .

The accompanying figures are intended to provide a further understanding of the embodiments of the invention. They illustrate embodiments and serve in conjunction with the description explaining principles and concepts of the invention. Other embodiments and many of the advantages mentioned emerge with a view to the drawings. The elements of the drawings are not necessarily shown to scale with one another.

In the figures of the drawing, identical, functionally identical and identically acting elements, features and components - unless stated otherwise - are each provided with the same reference symbols.

1 Figure 3 shows a schematic view of a 3D printing device 10 according to one embodiment of the invention. A schematic flow chart for a corresponding 3D printing process M. with the 3D printing device 10 is in 2 pictured. The 3D printing process M. and the 3D printing device 10 are used for the additive manufacturing of a propellant charge 2 for a solid-state engine 1 (see. 1 ), for example a missile such as a solid rocket or the like.

The 3D printing process M. fundamentally includes under M1 Laying down an extrudable modeling material in layers 3 in material layers 4th , wherein the extrudable modeling material 3 directly into an engine casing 8th of the solid-state engine 1 is filed. Furthermore, the 3D printing process includes M. under M2 Hardening of the extrudable modeling material 3 in the material layers 4th to form the propellant charge 2 .

In general, extrudable modeling materials include all materials that can be extruded with a suitable nozzle. In particular, extrudable modeling materials include flowable materials. However, non-flowable materials can also be used that can be processed (e.g. by heating) in such a way that they can be extruded. The viscosity of the material can be taken into account when choosing the specific extruder nozzle used.

This includes the extrudable modeling material 3 in this embodiment three different hardenable fuel mixtures by way of example 5a-5c : a first fuel mixture 5a , a second fuel mixture 5b and a third fuel mixture 5c . The first hardenable fuel mixture 5a is used in the first areas of the material layers 4th filed. The second hardenable fuel mixture is correspondingly 5b in the second areas of the material layers 4th and the third hardenable propellant mixture 5c in third areas of the material layers 4th filed.

The first, second and third areas are each different areas within the propellant charge 2 in the material layers 4th . An exemplary schematic arrangement is shown in FIG 1 shown. It goes without saying that the embodiment shown is to be understood only schematically and by way of example, and other arrangements of the fuel mixtures in other embodiments of the invention 5a-5c possible are. Furthermore, only two different fuel mixtures or more than three fuel mixtures can alternatively be used.

The first, second and third areas are in the material layers 4th for setting a predetermined thrust course of the solid-state engine 1 arranged and formed. By suitable choice of the properties of the fuel mixtures 5a-5c and their arrangement can in principle any thrust courses of the solid-state engine 1 can be set. For example, an inhomogeneous fuel distribution can be set in order to influence the course of the thrust in a targeted manner. Furthermore properties of the fuel mixtures 5a-5c such as thrust power and / or burn rate can be varied in order to manipulate the thrust further.

About the flexibility for setting the thrust course of the solid-state engine 1 The 3D printing process sees further improvement M. also the deposit of a hardenable inert, ie non-energetic or reactive, material 6th which is in the fourth areas of the material layers 4th is stored (cf. 1 ).

Material recesses can also be made in a similar manner 11 in the material layers 4th be left, for example, to form material-free channels that can further influence the burn rate or the burn rate.

In the specific exemplary embodiment according to 1 is in the middle of the propellant charge 2 along an axis of symmetry of the propellant charge 2 a channel-shaped material recess 11 leave that one ignition channel 9 forms. There is an ignition material for this purpose 7th at a lower end of the ignition channel 9 been filed. The third fuel mixture also surrounds it 5c the ignition channel 9 along a lateral surface of the ignition channel 9 . The burn rate of the third fuel mixture 5c is chosen to be significantly higher than that of the first and second fuel mixtures 5a , 5b in order to ignite the propellant charge as quickly and in particular as uniformly as possible 2 to reach.

The concrete distribution as well as the properties of the fuel mixtures 5a-5c , the inert material 6th as well as the material recesses 11 can can be calculated with a corresponding software for a desired thrust course.

The 3D printing process is carried out by the 3D printing device 10 in 1 . The 3D printing device 10 includes a print head 12th with a material mixer 13th for mixing the fuel mixtures 5a-5c as well as a pressure nozzle 18th for storing the fuel mixes 5a-5c . To this end, the 3D printing device includes 10 multiple material containers 21 for the individual components of the fuel mix 5a-5c . Specifically, the 3D printing device includes 10 in the execution according to 1 a material container 21 for a fuel 14th , a material container 21 for a binder 15th , a material container 21 for a hardener 16 and a material container 21 for an additive 17th . There is also a material container 21 for the inert material 6th intended. The material container 21 are now with the material mixer 13th via flexible delivery lines 22nd connected to this with the appropriate materials for the mixture of a certain fuel mixture 5a-5c to supply.

It goes without saying that the specific number of material containers 21 and materials in 1 is to be understood purely by way of example and the person skilled in the art can mix or use more or less different materials depending on the application, eg several fuels, binders, hardeners and / or additives, or can also omit certain components. For example, a binder 15th be provided with a UV curing binder. Instead, the deposited modeling material 3 with UV lighting 20th be irradiated.

Furthermore, in the exemplary embodiment according to 1 a single printhead 12th used to print all materials, especially the different fuel mixtures 5a-5c . In alternative embodiments, however, the person skilled in the art can also provide several print heads, for example for each fuel mixture 5a-5c a separate printhead.

The printhead 12th in execution in 1 has at least three degrees of freedom of movement, for example along the three spatial axes, around the modeling material 3 as flexible as possible in the engine shell 8th to be able to take off.

In the execution in 1 is also an alignment device for this purpose 19th provided, which is designed to be the engine casing 8th of the solid-state engine 1 for the immediate depositing of the extrudable modeling material 3 into the engine shell 8th align. For example, the alignment device 19th to be designed, the engine casing 8th to rotate around another axis. In addition, the print head 12th for example in relation to the engine casing 8th be tilted.

As a result, it becomes a 3D printing apparatus 10 or a 3D printing process M. provided, which enables the production of practically any thrust courses in a uniform, inexpensive and simple process.

In the preceding detailed description, various features for improving the stringency of the presentation have been summarized in one or more examples. It should be clear, however, that the above description is merely illustrative and in no way restrictive in nature. It serves to cover all alternatives, modifications and equivalents of the various features and exemplary embodiments. Many other examples will be immediately and immediately apparent to those skilled in the art on the basis of their technical knowledge in view of the above description.

The exemplary embodiments were selected and described in order to be able to illustrate the principles on which the invention is based and their possible applications in practice as well as possible. As a result, those skilled in the art can optimally modify and use the invention and its various exemplary embodiments with regard to the intended use. In the claims and the description, the terms “including” and “having” are used as neutral-language terms for the corresponding terms “comprising”.

Furthermore, the use of the terms “a”, “an” and “an” should not fundamentally exclude a plurality of features and components described in this way.

List of reference symbols

1

Solid-state engine

2

Propellant charge

3

extrudable modeling material

4th

Material position

5a-c

curable fuel mixture

6th

inert material

7th

Ignition material

8th

Engine casing

9

Ignition channel

10

3D printing device

11

Material recess

12th

Printhead

13th

Material mixer

14th

fuel

15th

binder

16

Harder

17th

Additive

18th

Pressure nozzle

19th

Alignment device

20th

UV lighting

21

Material container

22nd

flexible delivery line

M.

3D printing process

M1-M2

Procedural steps

QUOTES INCLUDED IN THE DESCRIPTION

This list of the documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Non-patent literature cited

• Chandru et al., "Additive Manufacturing of Solid Rocket Propellant Grains," Journal of Propulsion and Power, Volume 34, No. 4, 2018 [0003]

Claims (14)

3D printing process (M) for the additive manufacturing of a propellant charge (2) for a solid-state engine (1), with: Laying down (M1) of an extrudable modeling material (3) in layers (4), the extrudable modeling material (3) comprising at least two different hardenable fuel mixtures (5a-5c), with a first hardenable fuel mixture (4) in the first areas of the material layers (4). 5a) and in second areas of the material layers (4), which differ from the first areas, a second hardenable fuel mixture (5b) is deposited, the first areas and the second areas in the material layers (4) for setting a predetermined thrust course of the Solid-state propulsion unit (1) are arranged; and Curing (M2) of the extrudable modeling material (3) in the material layers (4) to form the propellant charge (2). 3D printing process (M) according to Claim 1 , the extrudable modeling material (3) being deposited in such a way that an inhomogeneous fuel distribution is created in the propellant charge (2). 3D printing process (M) according to one of the Claims 1 and 2 , wherein the different hardenable fuel mixtures (5a-5c) have different thrust and / or burn rates. 3D printing process (M) according to one of the Claims 1 to 3 , wherein the extrudable modeling material (3) further comprises a hardenable inert material (6) which is deposited in third areas of the material layers (4) which differ from the first areas and the second areas, the inert material (6) after Curing defined areas in the propellant charge (2). 3D printing process (M) according to one of the Claims 1 to 4th , further with: depositing an ignition material (7) in the material layers (4) to form an igniter for igniting the propellant charge (2) of the solid-state engine (1). 3D printing process (M) according to one of the Claims 1 to 5 , the extrudable modeling material (3) being deposited directly into an engine casing (8) of the solid-state engine (1). 3D printing process (M) according to one of the Claims 1 to 6th , wherein the extrudable modeling material (3) comprises at least a third hardenable fuel mixture (5c), which has a higher burn rate than the first hardenable fuel mixture (5a) and the second hardenable fuel mixture (5b), the third hardenable fuel mixture (5c) in such a way the material layers (4) is deposited so that an ignition channel (9) with the third fuel mixture (5c) is formed in the propellant charge (2). 3D printing process (M) according to one of the Claims 1 to 7th wherein material-free channels are formed in the propellant charge (2) through material recesses (11) in the material layers (4). 3D printing device (10), which is used for the additive manufacture of a propellant charge (2) for a solid-state engine (1) with a 3D printing process (M) according to one of the Claims 1 to 8th is trained. 3D printing device (10) according to Claim 9 , wherein the 3D printing device (10) has a print head (12) which comprises: a material mixer (13) for mixing a fuel (14) with at least one from the group comprising a binder (15), a hardener (16) and an additive (17) to a fuel mixture (5a-5c); and a pressure nozzle (18) for depositing the fuel mixture (5a-5c). 3D printing device (10) according to one of the Claims 9 and 10 wherein the binder (15) comprises a UV-curing binder. 3D printing device (10) according to one of the Claims 9 to 11 , wherein the 3D printing device (10) has a separate print head (12) for each fuel mixture (5a-5c) and / or for a hardenable inert material (6). 3D printing device (10) according to one of the Claims 9 to 12th , further comprising: an alignment device (19) which is designed to align an engine casing (8) of the solid-state engine (1) for the direct depositing of the extrudable modeling material (3) in the engine casing (8). Computer-readable medium on which computer-executable instructions are stored which, when executed by means of a data processing device, cause the data processing device to perform a 3D printing method (M) according to one of the Claims 1 to 8th to execute.

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